power steering gear box abutting frame

[plothead]

Hi Team

The original power steering box I grabbed 25 years ago had the bottom of the sector shaft cut off, but I was able to grab a rebuilt 4-turn from a '76 or '77 at a price that worked for me.
So that is resolved.

I'm looking at where the PS box attaches to the frame, though, and the people who originally put in an aftermarket (Toyota) power steering box welded a 5/16"-ish reinforcement plate on the outside face of the frame (towards the fender). As I understand it, this usually goes on the inside face of the frame (toward the engine).

This causes my rebuilt '76-'77 Bronco PS box to butt up to this reinforcement plate about 1/4" away from the frame toward the fender.

Will this be an issue?

Thanks for all the wisdom.
CD

 

[1969]

I welded plate to both sides of my frame and sleeved the holes, and got the proper length bolts. As long as the box is mounted flush you will be fine.

 

[DirtDonk]

I’ve seen where the really thick 5/8 or 3/4 inch thick plates will make the coupler hit the inner wheel well. But 5/16 inch thick plate shouldn’t be a huge problem.

 

[DirtDonk]

This causes my rebuilt '76-'77 Bronco PS box to butt up to this reinforcement plate about 1/4" away from the frame toward the fender.

Then again, I’m having a difficult time visualizing just what you’re saying here. Care to elaborate or show us a picture?

 

[plothead]

@DirtDonk, back-of-the-envelope section through the frame...thanks for the input, gang

 

[DirtDonk]

Frankly, I always liked the idea of a reinforcement plate on the frame. Maybe even both sides.
But my peeve with the ultra thick ones was that they push the box out just too far, for (at least as far as I could see) no additional benefit.
A quarter, or 3/16, or even just a 1/8 plate would be a nice improvement over nothing. At least for most of us.
The super hard core users here (you know who you are!) might benefit from more beef. But those of us that have never cracked a stock frame, would be fine with less.

 

[DirtDonk]

In answer to the question I think you’re asking, though, is that no, unless it causes physical interference with something, it shouldn’t be a problem.
The steering shaft can usually handle that slight offset. Drag link can usually handle that slight offset, especially if you have an adjustable aftermarket unit. And I can’t remember ever hearing of any issues with linkage, steering feel, or road manners, due to using a reinforcing plate.
Maybe there have been members complaining about not fully turning in one direction versus the other?
I don’t remember hearing that applied to a frame plate, but it certainly has been caused by plenty of other modifications.
Such as lift kits and such.

 

[plothead]

Thanks much, Dirt.
I have an adjustable drag link, which can be adjusted to correct any offset.

Given the setup I have, do you think I also need to add a plate on the inner, engine side of the frame?
Thanks,
CD

 

[DirtDonk]

No, and yes.
What are your plans uses for the Bronco?
What size tires are you running?
What size wheels and backspacing/offset?
Things like that will make a difference.

If this is normal use, forget about adding another plate. It’s just not needed.
If you’re building a big-tire rock buggy, then by all means reinforce it.
But remember this, if you’re building a rock buggy with the stock box, the frame might be the least of your worries. The stock box will grenade at some point with larger tires and hard use.
Then again, under those circumstances, upgrading both would be a good idea.

 

[jamesroney]

Hi Team

The original power steering box I grabbed 25 years ago had the bottom of the sector shaft cut off, but I was able to grab a rebuilt 4-turn from a '76 or '77 at a price that worked for me.
So that is resolved.

I'm looking at where the PS box attaches to the frame, though, and the people who originally put in an aftermarket (Toyota) power steering box welded a 5/16"-ish reinforcement plate on the outside face of the frame (towards the fender). As I understand it, this usually goes on the inside face of the frame (toward the engine).

This causes my rebuilt '76-'77 Bronco PS box to butt up to this reinforcement plate about 1/4" away from the frame toward the fender.

Will this be an issue?

Thanks for all the wisdom.
CD

Well, you kinda have to answer the question that you didn't ask. "Why did the previous owner install that plate?"

Bear in mind that a plate in that location, using the factory holes, with correct sleeves...does nothing. You call it a reinforcing plate, but what exactly is is reinforcing? That side of the frame bolts flush against the steering box. So adding a plate in that location does nothing to prevent pull thru, twist, or bending. So the ONLY reason to add a plate on that side is to allow you to install a Toyota box with different bolt pattern...and NOT add the correct compression sleeves. OR, to scab over and hide a cracked, rusty, or broken frame.

My guess is that you will find the inner side of your frame has some "extra" holes in it for the Aisin box. If so, did the original installer modify, cut out, or change the factory compression sleeves. If the sleeves are intact, and the proper torque can be achieved without crushing the frame...then you can leave it. But keep in mind that it is not actually doing anything of value, and always calls into question what you are hiding.

If it were mine, I would of course remove it, and weld up the excess holes on the inside. Unless it is welded very nicely, and finished properly, and looks attractive. Because it is purely cosmetic at this point, and I hate things that are cosmetic but still ugly.

 

[plothead]

Copy, thanks.
@DirtDonk, it's a street driver, 1.5" WH premium suspension lift , no body lift. 4-turn factory steering.
@jamesroney, the 1/4" plate and compression sleeves/inner frame reinforcement (1/4" thick steel tubes) are a BC Broncos reinforcement kit installed 25 years ago. Both the plate and sleeves were welded in. The inner fender has one extra hole, and where the stock box bolts poke through, they welded 1-1/2" x 1-1/2" x 1/4" steel plates (?). See my sketches, attached. The first image shows the inner side of the frame where the PS box bolts pass through; the second is a section through the frame, looking at the PS box from the front of the truck.
Thanks again, team.
CD

 

[jamesroney]

Is it Chuck’s 48-20011 steering box reinforcement plate? If so, those are an upgrade when properly installed.

 

[plothead]

Thanks for the feedback, folks.
The reinforcement is a version of Chuck's 48-20011 from around 2001 or so, back when they were still in CA.

 

[Broncobowsher]

The frame sometimes cracks around the mounting holes. People have been known to use the plate to double down on a crack repair from coming back.

 

[bigmuddy]

The frame sometimes cracks around the mounting holes. People have been known to use the plate to double down on a crack repair from coming ba

A previous owner added an 1/8 piece of channel under the PS box on my rig. Always assumed it was due to a crack or possible to keep the frame from crushing in that area? Certainly wasn't due to rust as this one was 99% rust free when I picked it up.
I had some minor clearance with the pitman arm wearing on the bottom side where the channel wrapped under the frame but some grinder/sander work clearanced it nicely and I feel better with it there.